ABSTRACT

Due to the continuous demand for miniature products, demand for microtool increases. Various conventional and non-conventional methods have been employed for the fabrication of microtool. In this paper, electrochemical micromachining (EMM) is used for the fabrication of microtool as it offers good accuracy, no heat generation, contactless process, no tool wear and good surface finish. The microtool of different shape and sizes are fabricated from Tungsten tool having initial diameter of 500 µm using the two different techniques. In the first technique, the tool is placed inside the pre-made hole in stainless steel (SS) plate and the effect of tool rotation is analyzed. In the second technique, the tool is kept adjacent to SS plate and the analysis is based on the interelectrode gap (IEG) during machining. COMSOL® Multiphysics software is used to create a 2D model to study the variation of current density distribution in the interelectrode gap. First technique with tool rotation results in conical microtool with good surface finish and second technique results in cylindrical microtool with diameter less than 100 µm. Simulation results are validated with the experimental results with an error below 15%.

摘要

由于对微型产品的持续需求，对微型工具的需求增加。各种传统和非常规方法已被用于制造微型工具。在本文中，电化学微加工 (EMM) 用于制造微型工具，因为它具有良好的精度、不发热、非接触式工艺、无工具磨损和良好的表面光洁度。不同形状和尺寸的微型工具使用两种不同的技术由初始直径为 500 µm 的钨工具制成。在第一种技术中，工具被放置在不锈钢 (SS) 板的预制孔内，并分析工具旋转的影响。在第二种技术中，刀具保持与 SS 板相邻，分析基于加工过程中的极间间隙 (IEG)。COMSOL® Multiphysics 软件用于创建二维模型来研究电极间间隙中电流密度分布的变化。第一种工具旋转技术产生具有良好表面光洁度的锥形微型工具，第二种技术产生直径小于 100 µm 的圆柱形微型工具。仿真结果与实验结果相验证，误差低于15%。